Steam generation processes utilizing biomass feedstocks

ABSTRACT

Integrated catalytic gasification processes are provided involving generating steam for converting carbonaceous materials to combustible gases, such as methane. Generally, steam generated from the combustion of a biomass is provided to a catalytic gasifier, wherein under appropriate temperature and pressure conditions, a carbonaceous feedstock is converted into a plurality of product gases, including, but not limited to, methane, carbon monoxide, hydrogen, and carbon dioxide.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority under 35 U.S.C. §119 from U.S. Provisional Application Ser. No. 61/032,713 (filed Feb. 29, 2008), the disclosure of which is incorporated by reference herein for all purposes as if fully set forth.

FIELD OF THE INVENTION

The present invention relates to methods for the production of steam for use in a catalytic gasification reactor which have a reduced carbon footprint. In particular, the present invention relates to the use of biomass for the generation of steam for use in the catalytic gasification of a carbonaceous material to yield, in particular, methane.

BACKGROUND OF THE INVENTION

In view of numerous factors such as higher energy prices and environmental concerns, the production of value-added gaseous products from lower-fuel-value carbonaceous feedstocks, such as biomass, coal and petroleum coke, is receiving renewed attention. The catalytic gasification of such materials to produce methane and other value-added gases is disclosed, for example, in U.S. Pat. No. 3,828,474, U.S. Pat. No. 3,998,607, U.S. Pat. No. 4,057,512, U.S. Pat. No. 4,092,125, U.S. Pat. No. 4,094,650, U.S. Pat. No. 4,204,843, U.S. Pat. No. 4,468,231, U.S. Pat. No. 4,500,323, U.S. Pat. No. 4,541,841, U.S. Pat. No. 4,551,155, U.S. Pat. No. 4,558,027, U.S. Pat. No. 4,606,105, U.S. Pat. No. 4,617,027, U.S. Pat. No. 4,609,456, U.S. Pat. No. 5,017,282, U.S. Pat. No. 5,055,181, U.S. Pat. No. 6,187,465, U.S. Pat. No. 6,790,430, U.S. Pat. No. 6,894,183, U.S. Pat. No. 6,955,695, US2003/0167961A1, US2006/0265953A1, US2007/000177A1, US2007/083072A1, US2007/0277437A1 and GB 1599932.

The process for the catalytic gasification of a carbonaceous material to synthetic natural gas requires the presence of steam to react with carbon to generate methane and carbon dioxide. It has generally been contemplated to utilize coal-fired boilers to generate the required steam. Such methods have the disadvantages of requiring an additional fuel source for the boiler, while producing an exhaust comprising carbon dioxide, which may be exhausted to the atmosphere, representing a substantial carbon footprint for the process. As such, there exists a need in the art to develop processes for the catalytic gasification of carbonaceous materials to synthetic natural gas which more efficiently utilize fuels sources, including those utilized for generating steam, while decreasing the carbon footprint of the overall process.

SUMMARY OF THE INVENTION

In a first aspect, the invention provides a process for converting a carbonaceous feedstock into a plurality of gaseous products, the process comprising the steps of: (A) supplying a biomass feedstock to a reactor; (B) at least partially combusting the biomass feedstock in the reactor in the presence of an oxygen-containing gas and under suitable temperature and pressure to generate heat energy; (C) utilizing the heat energy to generate steam; (D) introducing a carbonaceous feedstock, an alkali metal gasification catalyst, and at least a portion of the steam to a gasifier; (E) reacting the carbonaceous feedstock in the gasifier in the presence of the steam and the alkali metal gasification catalyst and under suitable temperature and pressure to form a gas stream comprising a plurality of gaseous products comprising methane and at least one or more of hydrogen, carbon monoxide, carbon dioxide, hydrogen sulfide, ammonia and other higher hydrocarbons; and (F) at least partially separating the plurality of gaseous products to produce a product stream comprising a predominant amount of one of the gaseous products.

In a second aspect, the invention provides a process for converting a carbonaceous feedstock into a plurality of gaseous products, and generating electricity, the process comprising the steps of: (A) supplying a biomass feedstock to a reactor; (B) at least partially combusting the biomass feedstock in the reactor in the presence of an oxygen-containing gas and under suitable temperature and pressure to generate heat energy; (C) utilizing the heat energy to generate steam; (D) dividing the steam into at least a first steam stream and a second steam stream; (E) introducing the first steam stream, a carbonaceous feedstock and an alkali metal gasification catalyst to a gasifier; (F) introducing the second steam stream to a steam turbine to generate electricity; (G) reacting the carbonaceous feedstock in the gasifier in the presence of the first steam stream and the alkali metal gasification catalyst and under suitable temperature and pressure to form a gas stream comprising a plurality of gaseous products comprising methane and at least one or more of hydrogen, carbon monoxide, carbon dioxide, hydrogen sulfide, ammonia and other higher hydrocarbons; (H) at least partially separating the plurality of gaseous products to produce a product stream comprising a predominant amount of one of the gaseous products.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a flow chart illustrating a method for generating combustible gases according to an embodiment of the present invention.

DETAILED DESCRIPTION

The present invention relates to methods for generating steam for providing to a catalytic gasification reactor, which methods result in reduced carbon footprints. Such methods can be integrated into processes for the catalytic gasification of a carbonaceous feedstock and/or for generating electricity.

The present invention can be practiced, for example, using any of the developments to catalytic gasification technology disclosed in commonly owned US2007/0000177A1, US2007/0083072A1 and US2007/0277437A1; and U.S. patent application Ser. No. 12/178,380 (filed 23 Jul. 2008), Ser. No. 12/234,012 (filed 19 Sep. 2008) and Ser. No. 12/234,018 (filed 19 Sep. 2008). All of the above are incorporated by reference herein for all purposes as if fully set forth.

Moreover, the present invention can be practiced in conjunction with the subject matter of the following U.S. Patent Applications, each of which was filed on Dec. 28, 2008: Ser. No. 12/342,554, entitled “CATALYTIC GASIFICATION PROCESS WITH RECOVERY OF ALKALI METAL FROM CHAR”; Ser. No. 12/342,565, entitled “PETROLEUM COKE COMPOSITIONS FOR CATALYTIC GASIFICATION”; Ser. No. 12/342,578, entitled “COAL COMPOSITIONS FOR CATALYTIC GASIFICATION”; Ser. No. 12/342,596, entitled “PROCESSES FOR MAKING SYNTHESIS GAS AND SYNGAS-DERIVED PRODUCTS”; Ser. No. 12/342,608, entitled “PETROLEUM COKE COMPOSITIONS FOR CATALYTIC GASIFICATION”; Ser. No. 12/342,628, entitled “PROCESSES FOR MAKING SYNGAS-DERIVED PRODUCTS”; Ser. No. 12/342,663, entitled “CARBONACEOUS FUELS AND PROCESSES FOR MAKING AND USING THEM”; Ser. No. 12/342,715, entitled “CATALYTIC GASIFICATION PROCESS WITH RECOVERY OF ALKALI METAL FROM CHAR”; Ser. No. 12/342,736, entitled “CATALYTIC GASIFICATION PROCESS WITH RECOVERY OF ALKALI METAL FROM CHAR”; Ser. No. 12/343,143, entitled “CATALYTIC GASIFICATION PROCESS WITH RECOVERY OF ALKALI METAL FROM CHAR”; Ser. No. 12/343,149, entitled “STEAM GENERATING SLURRY GASIFIER FOR THE CATALYTIC GASIFICATION OF A CARBONACEOUS FEEDSTOCK”; and Ser. No. 12/343,159, entitled “CONTINUOUS PROCESSES FOR CONVERTING CARBONACEOUS FEEDSTOCK INTO GASEOUS PRODUCTS”. All of the above are incorporated by reference herein for all purposes as if fully set forth.

Further, the present invention can be practiced in conjunction with the subject matter of the following U.S. Patent Applications, each of which was filed concurrently herewith: Ser. No. 12/395,293, entitled “PROCESSES FOR MAKING ABSORBENTS AND PROCESSES FOR REMOVING CONTAMINANTS FROM FLUIDS USING THEM”; Ser. No. 12/395,320, entitled “REDUCED CARBON FOOTPRINT STEAM GENERATION PROCESSES”; Ser. No. 12/395,330, entitled “PROCESS AND APPARATUS FOR THE SEPARATION OF METHANE FROM A GAS STREAM”; Ser. No. 12/395,344, entitled “SELECTIVE REMOVAL AND RECOVERY OF ACID GASES FROM GASIFICATION PRODUCTS”; Ser. No. 12/395,348, entitled “COAL COMPOSITIONS FOR CATALYTIC GASIFICATION”; Ser. No. 12/395,353, entitled “COAL COMPOSITIONS FOR CATALYTIC GASIFICATION”; Ser. No. 12/395,372, entitled “CO-FEED OF BIOMASS AS SOURCE OF MAKEUP CATALYSTS FOR CATALYTIC COAL GASIFICATION”; Ser. No. 12/395,381, entitled “COMPACTOR-FEEDER”; Ser. No. 12/395,385, entitled “CARBONACEOUS FINES RECYCLE”; Ser. No. 12/395,429, entitled “BIOMASS CHAR COMPOSITIONS FOR CATALYTIC GASIFICATION”; Ser. No. 12/395,433, entitled “CATALYTIC GASIFICATION PARTICULATE COMPOSITIONS”; and Ser. No. 12/395,447, entitled “BIOMASS COMPOSITIONS FOR CATALYTIC GASIFICATION”. All of the above are incorporated herein by reference for all purposes as if fully set forth.

All publications, patent applications, patents and other references mentioned herein, if not otherwise indicated, are explicitly incorporated by reference herein in their entirety for all purposes as if fully set forth.

Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. In case of conflict, the present specification, including definitions, will control.

Except where expressly noted, trademarks are shown in upper case.

Although methods and materials similar or equivalent to those described herein can be used in the practice or testing of the present invention, suitable methods and materials are described herein.

Unless stated otherwise, all percentages, parts, ratios, etc., are by weight.

When an amount, concentration, or other value or parameter is given as a range, or a list of upper and lower values, this is to be understood as specifically disclosing all ranges formed from any pair of any upper and lower range limits, regardless of whether ranges are separately disclosed. Where a range of numerical values is recited herein, unless otherwise stated, the range is intended to include the endpoints thereof, and all integers and fractions within the range. It is not intended that the scope of the present invention be limited to the specific values recited when defining a range.

When the term “about” is used in describing a value or an end-point of a range, the invention should be understood to include the specific value or end-point referred to.

As used herein, the terms “comprises,” “comprising,” “includes,” “including,” “has,” “having” or any other variation thereof, are intended to cover a non-exclusive inclusion. For example, a process, method, article, or apparatus that comprises a list of elements is not necessarily limited to only those elements but can include other elements not expressly listed or inherent to such process, method, article, or apparatus. Further, unless expressly stated to the contrary, “or” refers to an inclusive or and not to an exclusive or. For example, a condition A or B is satisfied by any one of the following: A is true (or present) and B is false (or not present), A is false (or not present) and B is true (or present), and both A and B are true (or present).

The use of “a” or “an” to describe the various elements and components herein is merely for convenience and to give a general sense of the invention. This description should be read to include one or at least one and the singular also includes the plural unless it is obvious that it is meant otherwise.

The materials, methods, and examples herein are illustrative only and, except as specifically stated, are not intended to be limiting.

Steam Generation Methods

The steam generating processes of the present invention are particularly useful in an integrated catalytic gasification process for converting carbonaceous materials to combustible gases, such as methane, while achieving a low or near zero carbon footprint. In some cases, the carbon footprint may be negative if the exhaust gas produced from the steam generation processes are directed through the catalytic gasification processes, as described herein.

A typical flow chart for integration into a process for generating a combustible gas from a carbonaceous feedstock is illustrated in FIG. 1, and referenced herein. Generally, steam and a carbonaceous feedstock are provided to a gasifier (200), wherein under appropriate temperature and pressure conditions, and in the presence of one or more gasification catalysts, the carbonaceous feedstock is converted into a plurality of product gases, including, but not limited to, methane, carbon monoxide, hydrogen, carbon dioxide, ammonia, and hydrogen sulfide.

In the present processes, the steam provided to the gasifier (200) is generated from action of reactor (100) and is conveyed via a heated gas conduit (110) from the reactor to the catalytic gasifier (200). Reactor (100) includes, but is not limited to, commercial gasification reactors, oxy-fuel combustors, and boilers. Reactor (100) is fed with a biomass feedstock (404), from a feedstock preparation operation (400), and generally, may comprise one or a mixture of biomass materials, as defined herein.

The partial or complete gasification or partial or complete combustion of the biomass feedstock (404) in reactor (100) generates large amounts of heat energy and an exhaust gas comprising carbon dioxide.

Advantageously, this heat energy can be used to contact any type of heat exchanger, in contact with a water source, to generate steam. For example, any of the boilers known to those skilled in the art can be fueled by the biomass feedstock (404) to supply steam to gasifier (200). While any water source can be used to generate steam, the water commonly used in known boiler systems is purified and deionized (about 0.3-1.0 μS/cm) so that corrosive processes are slowed. Such boilers can be powered, for example, through the oxygen-blown combustion of any biomass material. Ultimately, the thermal energy from the gasification or combustion of the biomass feedstock (404) may heat a water source in communication with reactor (100), to produce steam (typically at about 1300° F. and 500 psi).

The steam produced by action of the reactor (100) can be generally variable based on the type of reactor and feedstock being utilized. Preferably, the steam can be provided to the catalytic gasifier in the range of about 550 to about 600 psia and about 1300 to about 1400° F. (about 700 to about 760° C.). More preferably, reactor (100) produces steam at a pressure essentially the same as the conditions being utilized in the catalytic gasifier (200), as any excess heat can be more efficiently captured for use in other operations (e.g., feedstock drying).

In another example, the contacting of water with the heat energy to produce steam may occur within reactor (100) either by the addition of water to the reactor via a separate feed line (not shown in FIG. 1), or by supplying the biomass feedstock (404), for example, as an aqueous slurry comprising a biomass particulate. In such cases, the steam can be generated as a gaseous mixture further comprising either (i) carbon dioxide, when reactor (100) is a combustor; or (ii) carbon monoxide, hydrogen and (optionally) carbon dioxide when reactor (100) is a gasifier. For example, steam can be generated within a gasifier which produces steam and synthesis gas from an aqueous biomass slurry, such as described in previously incorporated U.S. patent application Ser. No. 12/343,149.

The steam generated by reactor (100) may be routed, in whole or in part, into one or more heated conduits (105), which may be located at or near an exit conduit carrying the combustion gases, when present. For example, the steam can be divided into a plurality of steam streams (e.g., into at least a first and second steam stream), each comprising a portion of the steam. The portion of the steam which is provided to each stream may be controlled according to methods known in the art. Each steam stream can be routed in a variety of directions. For example, one or more steam streams may be provided the gasification reactor via a heated conduit (110); or one or more steam streams can be used to dry a carbonaceous feedstock (e.g., via heated conduit 130); or one or more steam streams can be routed to a steam turbine (2000, via heated conduit 140) for generation of electricity (2001). In order to avoid excessive cooling of the steam during transport, the contents of the heated conduits may be superheated according to methods known to those skilled in the art (e.g., via contact with a heat exchanger) prior to delivery of the steam to any endpoint. In one particular example, all the steam generated from reactor (100) is provided to gasifier (200).

A separate exhaust gas may be generated from combustion of the biomass feedstock in reactor (100), which may be (i) exhausted from the process; (ii) supplied with the generated steam via heated conduit (110) to gasifier (200); or (iii) supplied to gasifier (200) via a second heated conduit (120) (i.e., the exit conduit). By optionally directing the exhaust gas from reactor (100) through the catalytic gasifier (200) and the associated gas purification and separation unit operations (infra), essentially all the carbon dioxide produced from the steam generation process as well as from the gasification of a carbonaceous material may be recovered, yielding an overall catalytic gasification process having a near zero, or possibly negative, carbon footprint.

By “carbon footprint”, reference is made to the carbon dioxide released into the environment from non-biomass sources, for example, from the combustion of fossil fuels and release of the resulting carbon dioxide into the atmosphere. Capture and sequestration of all carbon dioxide generated from non-biomass sources would be considered to have a neutral carbon footprint, as no carbon dioxide would have been released into the atmosphere.

By contrast, the release of carbon dioxide into the atmosphere from biomass sources is considered carbon footprint neutral, since biomass is created (for example, directly as a plant, or indirectly as part of the food chain) by the capture and conversion of carbon dioxide from the atmosphere. As such, the capture and sequestration of carbon dioxide generated from biomass sources can actually result in a negative (reduced) carbon footprint.

Steam can also be supplied from a second gasification reactor (100) coupled with a combustion turbine, the exhaust gas of which contacts a heat exchanger in contact with a water source (e.g., a boiler system), to produce steam. The steam and exhaust gas (from the combustion turbine) may be directed as discussed previously.

Recycled steam from other process operations can also be used for supplementing steam to the catalytic gasifier. For example, in the preparation of a particulate carbonaceous feedstock, when a slurried particulate composition is dried with a fluid bed slurry drier, as discussed below, then the generated steam may be fed to the catalytic gasification reactor (200).

The small amount of required heat input for the catalytic gasifier (200) can be provided by, for example, superheating the steam provided to the gasifier; or superheating a mixture of the steam and any second gas source feeding the gasification reactor (e.g., the exhaust from reactor (100)). In one embodiment, compressed recycle gas comprising CO and H₂ (902, infra) can be mixed with the steam and the resulting steam/recycle gas mixture can be further superheated by heat exchange with the catalytic gasifier effluent followed by superheating in a recycle gas furnace for introduction into gasifier (200).

Catalytic Gasification Methods

Catalytic gasifier (200) utilizes a gas comprising steam, and optionally, other gases such as oxygen or air, carbon monoxide and hydrogen, for pressurization and reactions of the carbonaceous feedstock. The catalytic gasification reactor (200) can be operated at moderately high pressures and temperature. Typically, a carbonaceous feedstock (405) and a gasification catalyst (e.g., an alkali metal gasification catalyst) are introduced to a reaction zone of the catalytic gasifier (200) while maintaining the required temperature, pressure, and flow rate of the feedstock. Those skilled in the art are familiar with feed systems for providing feedstocks to high pressure and/or temperature environments, including, star feeders, screw feeders, rotary pistons, and lock-hoppers. It should be understood that the feed system can include two or more pressure-balanced elements, such as lock hoppers, which would be used alternately.

The carbonaceous feedstock and gasification catalyst may be introduced separately or combined as a catalyzed feedstock (infra) and are provided to the catalytic gasifier (200) from a feedstock preparation operation (400). In some instances, the carbonaceous feedstock (405) can be prepared at pressures conditions above the operating pressure of catalytic gasifier. Hence, the carbonaceous feedstock (405) may be directly passed into the catalytic gasifier without further pressurization.

Any of several catalytic gasifiers (200) can be utilized in the process of the described herein. Suitable gasifiers include, but are not limited to, counter-current fixed bed, co-current fixed bed, fluidized bed, entrained flow, and moving bed reactors. A catalytic gasifier for gasifying liquid feeds, such as liquid petroleum residues, is disclosed in previously incorporated U.S. Pat. No. 6,955,695.

The pressure in the catalytic gasifier (200) typically can be from about 10 to about 100 atm (from about 150 to about 1500 psig). The gasification reactor temperature can be maintained around at least about 450° C., or at least about 600° C., or at least about 900° C., or at least about 750° C., or about 600° C. to about 700° C.; and at pressures of at least about 50 psig, or at least about 200 psig, or at least about 400 psig, to about 1000 psig, or to about 700 psig, or to about 600 psig.

In one embodiment, an optional methane reformer (1000) may be included in the process. For example, when reactor (100) is a gasification reactor, a methane reformer (1000) may supplement the recycle CO and H₂ stream, the exhaust gas (120, as shown in FIG. 1) and/or steam stream (110) from the reactor to ensure that enough recycle gas is supplied to the reactor so that the net heat of reaction is as close to neutral as possible (only slightly exothermic or endothermic), in other words, that the catalytic gasifier is run under substantially thermally neutral conditions. In such instances, methane (901 a) can be supplied for the reformer from the methane product (901), as described below.

Reaction of the carbonaceous feedstock (405) in the catalytic gasifier (200), in the presence of one or more gasification catalysts under the described conditions, provides a crude product gas. When the exhaust gas (120) from reactor (100) is provided in whole to the gasifier (200), the crude product gas can comprise essentially all the carbon dioxide produced from reactor (100) and gasifier (200). Additionally, both reactor (100) and gasifier (200) produce a char (102 and 202, respectively).

The char produced in the catalytic gasifier (202) is typically removed from the gasifier for sampling, purging, and/or catalyst recovery in a continuous or batch-wise manner. Methods for removing char are well known to those skilled in the art. One such method taught by EP-A-0102828, for example, can be employed. The char can be periodically withdrawn from the catalytic gasification reactor through a lock hopper system, although other methods are known to those skilled in the art.

Often, the char (202) is directed to a catalyst recovery and recycle process (300) to produce a recycled catalyst stream (301) and a depleted char. Processes have been developed to recover alkali metal from the solid purge in order to reduce raw material costs and to minimize environmental impact of a catalytic gasification process. For example, the char (202) can be quenched with recycle gas and water and directed to a catalyst recycling operation for extraction and reuse of the alkali metal catalyst. Particularly useful recovery and recycling processes are described in U.S. Pat. No. 4,459,138, as well as previously incorporated U.S. Pat. No. 4,057,512 and US2007/0277437A1, and previously incorporated U.S. patent application Ser. Nos. 12/342,554, 12/342,715, 12/342,736 and 12/343,143. Reference can be had to those documents for further process details.

Upon completion of catalyst recovery, the recovered catalyst stream (301) (as a solution or solid) may be directed to the second feedstock preparation unit (403) of the feedstock preparation operation (400), as described herein. The depleted char may be utilized as a co-feedstock for reactor (100) (not shown in FIG. 1).

The char (102) produced in reactor (100) is typically removed via similar methods to those described for the catalytic gasification reactor, and may be recovered and extracted to provide a leachate for preparing the carbonaceous feedstock (405), as described in previously incorporated U.S. patent application Ser. No. 12/395,433, entitled “CATALYTIC GASIFICATION PARTICULATE COMPOSITIONS”; or may be recovered and utilized, itself, as part of the second carbonaceous feedstock (405), as described in previously incorporated U.S. patent application Ser. No. 12/395,429, entitled “BIOMASS CHAR COMPOSITIONS FOR CATALYTIC GASIFICATION”.

Crude product gas effluent leaving the catalytic gasifier (200) can pass through a portion of the reactor which serves as a disengagement zone where particles too heavy to be entrained by the gas leaving the reactor (i.e., fines) are returned to the fluidized bed. The disengagement zone can include one or more internal cyclone separators or similar devices for removing fines and particulates from the gas. The gas effluent (201) passing through the disengagement zone and leaving the catalytic gasifier generally contains CH₄, CO₂, H₂ and CO, H₂S, NH₃, other higher hydrocarbons, unreacted steam, entrained fines, and other contaminants such as COS.

The gas stream from which the fines have been removed (201) can then be passed through a heat exchanger (500) to cool the gas and the recovered heat can be used to preheat recycle gas and generate high pressure steam (501). Residual entrained fines can also be removed by any suitable means such as external cyclone separators, optionally followed by Venturi scrubbers. The recovered fines can be processed to recover alkali metal catalyst then passed to the feedstock preparation process (400), returned to the catalytic gasification reactor, or directly recycled back to feedstock preparation as described in previously incorporated U.S. patent application Ser. No. 12/395,385, entitled “CARBONACEOUS FINES RECYCLE”.

The gas stream (502) from which the fines have been removed can be fed to a gas purification operation (600) comprising COS hydrolysis reactors (601) for COS removal (sour process) and further cooled in a heat exchanger to recover residual heat prior to entering water scrubbers (602) for ammonia recovery, yielding a scrubbed gas comprising at least H₂S, CO₂, CO, H₂, and CH₄. Methods for COS hydrolysis are known to those skilled in the art, for example, see U.S. Pat. No. 4,100,256. The residual heat from the scrubbed gas can be used to generate low pressure steam.

Scrubber water (605) and sour process condensate (604) can be processed to strip and recover H₂S, CO₂ and NH₃; such processes are well known to those skilled in the art. NH₃ can typically be recovered as an aqueous solution (e.g., 20 wt %). Alternatively, scrubber water (605) and sour process condensate (604) can be returned to reactor (100), thereby reducing overall process water usage and eliminating separate cleanup of these process streams.

A subsequent acid gas removal process (603) can be used to remove H₂S and CO₂ from the scrubbed gas stream by a physical absorption method involving solvent treatment of the gas to give a cleaned gas stream. Such processes involve contacting the scrubbed gas with a solvent such as monoethanolamine, diethanolamine, methyldiethanolamine, diisopropylamine, diglycolamine, a solution of sodium salts of amino acids, methanol, hot potassium carbonate or the like. One method can involve the use of Selexol® (UOP LLC, Des Plaines, Ill. USA) or Rectisol® (Lurgi AG, Frankfurt am Main, Germany) solvent having two trains; each train consisting of an H₂₅ absorber and a CO₂ absorber. The spent solvent(s) (607) containing H₂S, CO₂ and other contaminants can be regenerated by any method known to those skilled in the art, including contacting the spent solvent with steam or other stripping gas to remove the contaminants or by passing the spent solvent through stripper columns. Recovered acid gases can be sent for sulfur recovery processing; for example, any recovered H₂S from the acid gas removal and sour water stripping can be converted to elemental sulfur by any method known to those skilled in the art, including the Claus process. Sulfur can be recovered as a molten liquid. Stripped water can be directed for recycled use in preparation of the first and/or particulate carbonaceous feedstock. One method for removing acid gases from the scrubbed gas stream is described in previously incorporated U.S. patent application Ser. No. 12/395,344, entitled “SELECTIVE REMOVAL AND RECOVERY OF ACID GASES FROM GASIFICATION PRODUCTS”.

Advantageously, CO₂ generated in the integrated process, whether in the steam generation or catalytic gasification or both, can be recovered for subsequent use or sequestration, enabling a greatly decreased carbon footprint. Steam may be generated with a reduced carbon footprint as described in previously incorporated U.S. patent application Ser. No. 12/395,320, entitled “REDUCED CARBON FOOTPRINT STEAM GENERATION PROCESSES”.

The resulting cleaned gas stream (606) exiting the gas purification operation (600) contains mostly CH₄, H₂, and CO and, typically, small amounts of CO₂ and H₂O. The cleaned gas stream (606) can be further processed to separate and recover CH₄ by any suitable gas separation method (900) known to those skilled in the art including, but not limited to, cryogenic distillation and the use of molecular sieves or ceramic membranes, or via the generation of methane hydrate as disclosed in previously incorporated U.S. patent application Ser. No. 12/395,330, entitled “PROCESS AND APPARATUS FOR THE SEPARATION OF METHANE FROM A GAS STREAM”.

Typically, two gas streams can be produced by the gas separation process (900), a methane product stream (901) and a syngas stream (902, H₂ and CO). The syngas stream (902) can be compressed and recycled. One option can be to recycle the syngas steam directly to the catalytic gasifier (200). In one case, the recycled syngas is combined with the exhaust gas (120) from the reactor (100), and the mixture introduced into the catalytic gasification reactor. In another case, the recycled syngas (902) can be directed into reactor (100). When a fluid bed reactor is utilized for reactor (100), the syngas may provide fluidization or aid in fluidization of the reaction bed.

If necessary, a portion of the methane product (901 a) can be directed to a reformer, as discussed previously. The need to direct a portion of the methane product can be controlled, for example, by the ratio of CO to H₂ in the exhaust gas from reactor (100). Particularly, methane can be directed to a reformer (1000) to supplement (1001) the exhaust gas (120) supplied to the catalytic gasification reactor and, in some instance, provide a ratio of about 3:1 of H₂ to CO in the feed to the catalytic gasification reactor (200). A portion of the methane product can also be used as plant fuel for a gas turbine.

Biomass and Carbonaceous Feedstocks

The biomass feedstock supplied to the reactor (100) comprises any one or combination of biomasses. The carbonaceous feedstock may comprise any one or combination of non-biomass materials and/or any one or combination of biomass materials. Each of the biomass feedstock and carbonaceous feedstocks may comprise the same or different biomasses, when present. In one embodiment, the biomass, carbonaceous, or both feedstocks comprise biomass. In another embodiment, the carbonaceous feedstock comprises non-biomass carbonaceous material. In yet another embodiment, the carbonaceous feedstock comprises biomass and non-biomass carbonaceous material.

The biomass feedstock and carbonaceous feedstock may be supplied as a particulate. Each feedstock, independently, may have an average particle size of from about 25 microns, or from about 45 microns, up to about 500, or up to about 2500 microns. One skilled in the art can readily determine the appropriate particle size for the individual particulates and the biomass feedstock and particulate carbonaceous feedstocks. For example, when a fluid bed gasification reactor is used as reactor (100) and/or gasifier (200), the biomass feedstock and/or particulate carbonaceous feedstock can have an average particle size which enables incipient fluidization of the carbonaceous feedstock at the gas velocity used in the fluid bed gasification reactor.

The term “carbonaceous material” as used herein refers to any carbonaceous material including, but not limited to biomass, coal, petroleum coke, asphaltenes, liquid petroleum residues, used motor oil and other waste processed petroleum sources, untreated or treated sewage waste, garbage, plastics, wood and other biomass, or mixtures thereof. The carbonaceous materials for the feedstock can comprise carbon sources containing at least about 20%, or at least about 30%, or at least about 40%, or at least about 50%, or at least about 60%, or at least about 70%, or at least about 80% carbon by dry weight.

The term “biomass” as used herein refers to carbonaceous materials derived from recently (for example, within the past 100 years) living organisms, including plant-based biomass and animal-based biomass. For clarification, biomass does not include fossil-based carbonaceous materials, such as coal.

The term “plant-based biomass” as used herein means materials derived from green plants, crops, algae, and trees, such as, but not limited to, sweet sorghum, bagasse, sugarcane, bamboo, hybrid poplar, hybrid willow, albizia trees, eucalyptus, alfalfa, clover, oil palm, switchgrass, sudangrass, millet, jatropha, and miscanthus (e.g., Miscanthus×giganteus). Biomass further include wastes from agricultural cultivation, processing, and/or degradation such as corn cobs and husks, corn stover, straw, nut shells, vegetable oils, canola oil, rapeseed oil, biodiesels, tree bark, wood chips, sawdust, and yard wastes.

The term “animal-based biomass” as used herein means wastes generated from animal cultivation and/or utilization. For example, biomass includes, but is not limited to, wastes from livestock cultivation and processing such as animal manure, guano, poultry litter, animal fats, and municipal solid wastes (e.g., sewage).

The term “non-biomass”, as used herein, means those carbonaceous materials which are not encompassed by the term “biomass” as defined herein. For example, non-biomass includes, but is not limited to, anthracite, bituminous coal, sub-bituminous coal, lignite, petroleum coke, asphaltenes, liquid petroleum residues, or mixtures thereof.

The term “petroleum coke” as used herein includes (i) the solid thermal decomposition product of high-boiling hydrocarbon fractions obtained in petroleum processing (heavy residues); and (ii) the solid thermal decomposition product of processing tar sands (bituminous sands or oil sands) Such carbonization products include, for example, green, calcined, needle and fluidized bed petroleum coke. Petroleum coke is generally prepared via delayed coking or fluid coking. The petroleum coke can be residual material remaining after retorting tar sands (e.g., mined) are heated to extract any oil.

Resid petcoke can also be derived from a crude oil, for example, by coking processes used for upgrading heavy-gravity residual crude oil, which petroleum coke contains ash as a minor component, typically about 1.0 wt % or less, and more typically about 0.5 wt % of less, based on the weight of the coke. Typically, the ash in such lower-ash cokes predominantly comprises metals such as nickel and vanadium.

Tar sands petcoke can be derived from an oil sand, for example, by coking processes used for upgrading oil sand. Tar sands petcoke contains ash as a minor component, typically in the range of about 2 wt % to about 12 wt %, and more typically in the range of about 4 wt % to about 12 wt %, based on the overall weight of the tar sands petcoke. Typically, the ash in such higher-ash cokes predominantly comprises materials such as compounds of silicon and/or aluminum.

The petroleum coke can comprise at least about 70 wt % carbon, at least about 80 wt % carbon, or at least about 90 wt % carbon, based on the total weight of the petroleum coke. Typically, the petroleum coke comprises less than about 20 wt % percent inorganic compounds, based on the weight of the petroleum coke.

The term “liquid petroleum residue” as used herein includes both (i) the liquid thermal decomposition product of high-boiling hydrocarbon fractions obtained in petroleum processing (heavy residues—“resid liquid petroleum residue”) and (ii) the liquid thermal decomposition product of processing tar sands (bituminous sands or oil sands—“tar sands liquid petroleum residue”). The liquid petroleum residue is substantially non-solid; for example, it can take the form of a thick fluid or a sludge.

Resid liquid petroleum residue also can be derived from a crude oil, for example, by processes used for upgrading heavy-gravity crude oil distillation residue. Such liquid petroleum residue contains ash as a minor component, typically about 1.0 wt % or less, and more typically about 0.5 wt % of less, based on the weight of the residue. Typically, the ash in such lower-ash residues predominantly comprises metals such as nickel and vanadium.

Tar sands liquid petroleum residue can be derived from an oil sand, for example, by processes used for upgrading oil sand. Tar sands liquid petroleum residue contains ash as a minor component, typically in the range of about 2 wt % to about 12 wt %, and more typically in the range of about 4 wt % to about 12 wt %, based on the overall weight of the residue. Typically, the ash in such higher-ash residues predominantly comprises materials such as compounds of silicon and/or aluminum.

The term “coal” as used herein means peat, lignite, sub-bituminous coal, bituminous coal, anthracite, graphite, or mixtures thereof. In certain embodiments, the coal has a carbon content of less than about 85%, or less than about 80%, or less than about 75%, or less than about 70%, or less than about 65%, or less than about 60%, or less than about 55%, or less than about 50% by weight, based on the total coal weight. In other embodiments, the coal has a carbon content ranging up to about 85%, or up to about 80%, or up to about 75% by weight, based on total coal weight. Examples of useful coals include, but are not limited to, Illinois #6, Pittsburgh #8, Beulah (N.D.), Utah Blind Canyon, and Powder River Basin (PRB) coals. Anthracite, bituminous coal, sub-bituminous coal, and lignite coal may contain about 10 wt %, from about 5 to about 7 wt %, from about 4 to about 8 wt %, and from about 9 to about 11 wt %, ash by total weight of the coal on a dry basis, respectively. However, the ash content of any particular coal source will depend on the rank and source of the coal, as is familiar to those skilled in the art (see, for example, Coal Data: A Reference, Energy Information Administration, Office of Coal, Nuclear, Electric and Alternate Fuels, U.S. Department of Energy, DOE/EIA-0064(93), February 1995).

Asphaltenes typically comprise aromatic carbonaceous solids at room temperature, and can be derived, from example, from the processing of crude oil, oil shale, bitumen, and tar sands.

Catalyst Components

As noted above, the carbonaceous feedstock and gasification catalyst can be introduced to gasifier (200) separately or combined as a single catalyzed feedstock. Suitable gasification catalysts include, but are not limited to, alkali metals such as lithium, sodium, potassium, rubidium, cesium, and mixtures thereof. Particularly useful are potassium sources. Suitable alkali metal compounds include alkali metal carbonates, bicarbonates, formates, oxalates, amides, hydroxides, acetates, or similar compounds. For example, the catalyst can comprise one or more of Na₂CO₃, K₂CO₃, Rb₂CO₃, Li₂CO₃, Cs₂CO₃, NaOH, KOH, RbOH or CsOH, and particularly, potassium carbonate and/or potassium hydroxide.

The carbonaceous feedstock, in certain embodiments, further comprises an amount of an alkali metal component, as an alkali metal and/or an alkali metal compound, as well as optional co-catalysts, as disclosed in the previous incorporated references. Typically, the quantity of the alkali metal component in the composition is sufficient to provide a ratio of alkali metal atoms to carbon atoms ranging from about 0.01, or from about 0.02, or from about 0.03, or from about 0.04, to about 0.06, or to about 0.07, or to about 0.08. Further, the alkali metal is typically loaded onto a biomass or carbonaceous material to achieve an alkali metal content of from about 3 to about 10 times more than the combined ash content of the biomass or carbonaceous material (e.g., coal and/or petroleum coke), on a mass basis.

Methods for Preparing Biomass Feedstock

The biomass feedstock (404) comprises a particulate composition of one or more biomasses; while the carbonaceous feedstock (405) may comprise one or more non-biomass materials, optionally in combination with one or more biomass materials (i.e., one or more carbonaceous materials) and an alkali metal gasification catalyst.

Each of the carbonaceous materials (i.e., biomass and/or non-biomass) can each be separately crushed and/or ground according to any methods known in the art in a first feedstock preparation unit (401), such as via impact crushing and wet or dry grinding to yield particulates of each. Additional feedstock processing steps may be necessary depending on the qualities of the carbonaceous materials. For example, many biomasses, such as sewage, and carbonaceous materials containing high moisture levels, such as high-moisture coals, can require drying prior to crushing. Further, some caking coals can be partially oxidized according to methods known in the art to simplify gasification reactor operation. Depending on the method utilized for crushing and/or grinding of the materials, the resulting particulates can be sized (i.e., separated according to size) to provide an appropriate feedstock.

Any method known to those skilled in the art can be used to size the particulates. For example, sizing can be preformed by screening or passing the particulates through a screen or number of screens. Screening equipment can include grizzlies, bar screens, and wire mesh screens. Screens can be static or incorporate mechanisms to shake or vibrate the screen. Alternatively, classification can be used to separate the particulates. Classification equipment can include ore sorters, gas cyclones, hydrocyclones, rake classifiers, rotating trommels, or fluidized classifiers. The carbonaceous materials can be also sized or classified prior to grinding and/or crushing.

In one example, coal is typically wet ground and sized (e.g., to a particle size distribution of about 25 to 2500 microns) and then drained of its free water (i.e., dewatered) to a wet cake consistency. Examples of suitable methods for the wet grinding, sizing, and dewatering are known to those skilled in the art; for example, see previously incorporated U.S. patent application Ser. No. 12/178,380.

The biomass feedstock comprises one or more types of biomass that may be blended as can be determined by one skilled in the art to provide the biomass feedstock to reactor (100) depending on the nature of reactor (100; i.e., whether it is an oxy-combustor or gasifier). In various embodiments, the biomass feedstock may comprise an aqueous slurry of the biomass particulates (supra) and can be readily prepared by adding water to the particulates before or after blending, as necessary.

The carbonaceous materials can be treated to associate at least a first catalyst (e.g., gasification catalyst) therewith, to provide the carbonaceous feedstock (405) (i.e., catalyzed feedstock) for the gasifier (200). The materials (402) prepared in first feedstock preparation unit (401) may be provided to a second feedstock preparation unit (403), either as individual streams or a previously blended stream, wherein an alkali metal catalyst may be provided to any one or more of the streams or the blended stream. Any methods known to those skilled in the art can be used to associate one or more gasification catalysts with the materials. Such methods include but are not limited to, admixing with a solid catalyst source, impregnating the catalyst onto the carbonaceous material or the biomass according to, for example, incipient wetness impregnation, evaporative impregnation, vacuum impregnation, dip impregnation, and combinations of these methods. Gasification catalysts can be impregnated by slurrying the materials with a solution (e.g., aqueous) of the catalyst.

In some cases, a second catalyst (e.g., co-catalyst) can be provided; in such instances, the particulates can be treated in separate processing steps to provide the first catalyst and second catalysts according to any of the preceding processes. For example, the primary gasification catalyst can be supplied (e.g., a potassium and/or sodium source), followed by a separate treatment to provide a co-catalyst source. Alternatively, the first and second catalysts can be provided as a mixture in a single treatment; or the first and second catalysts can be provided to separate materials and the treated materials ultimately blended.

One particular method suitable for combining coals with the gasification catalysts and optional co-catalysts is via ion exchange as described in previously incorporated U.S. patent application Ser. No. 12/178,380. Various coals deficient in ion-exchange sites can be pre-treated to create additional ion-exchange sites to facilitate catalysts loading and/or association. Such pre-treatments can be accomplished by any method known to the art that creates ion-exchange capable sites and/or enhances the porosity of a coal feed (see, for example, previously incorporated U.S. Pat. No. 4,468,231 and GB1599932). Often, pre-treatment is accomplished in an oxidative manner using any oxidant known to the art.

Any suitable methods known to those skilled in the art may be utilized for blending various particulates for preparing the biomass feedstock and carbonaceous feedstock. Such methods include, but are not limited to, kneading, and vertical or horizontal mixers, for example, single or twin screw, ribbon, or drum mixers.

Ultimately, the biomass feedstock and carbonaceous feedstocks may be dried, under a flow of an inert gas, with a fluid bed slurry drier (i.e., treatment with superheated steam to vaporize the liquid), or the remaining liquids evaporated to provide feedstocks having a residual moisture content of, for example, less than about 8 wt %, or less than about 6 wt %, or less than about 4 wt %.

The each of the biomass feedstocks and carbonaceous feedstocks can be stored for future use or transferred to a feed operation for introduction into the reactor (100) or gasifier (200). Each feedstock can be conveyed to storage or feed operations according to any methods known to those skilled in the art, for example, a screw conveyer or pneumatic transport.

EXAMPLES Example 1 Feedstock Preparation

As-received coal (Powder River Basin) can be stage-crushed to maximize the amount of material having particle sizes ranging from about 0.85 to about 1.4 mm. The crushed coal can be slurried with an aqueous solution of potassium carbonate, dewatered, and dried via a fluid bed slurry drier to yield a catalyzed feedstock.

Switchgrass can be dried and crushed to produce a particulate having an average size of about 250 microns to provide a biomass feedstock.

Example 2 Catalytic Gasification

The switchgrass particulate of Example 1 can be provided to a combustion reactor fed by an enriched oxygen source. The resulting exhaust gas from the combustion reactor could contain hot CO₂. The exhaust gas can be passed through a heat exchanger in contact with water to produce steam. The generated steam can be superheated and then introduced to a fluidized bed gasification reactor (catalytic gasifier) supplied with the catalyzed feedstock of Example 1. The catalyzed feedstock can be introduced under a positive pressure of nitrogen. Typical conditions for the catalytic gasifier could be: total pressure, 500 psi and temperature, 1200° F. The effluent of the catalytic gasifier could contain methane, CO₂, H₂, CO, water, H₂S, ammonia, and nitrogen, which is passed to a scrubber to remove ammonia and an acid gas removal unit to remove H₂S and CO₂. The CO₂ can be recovered. 

We claim:
 1. A process for converting a carbonaceous feedstock into a plurality of gaseous products, the process comprising the steps of: (A) supplying a biomass feedstock to a reactor, wherein the biomass feedstock (i) is in particulate form, or (ii) comprises an aqueous slurry; (B) at least partially combusting the biomass feedstock in the reactor in the presence of an oxygen-containing gas and under suitable temperature and pressure to generate heat energy and an exhaust comprising carbon dioxide; (C) utilizing the heat energy to generate steam; (D) introducing a carbonaceous feedstock, an alkali metal gasification catalyst, and at least a portion of the steam to a gasifier; (E) reacting the carbonaceous feedstock in the gasifier in the presence of the steam and the alkali metal gasification catalyst, at a temperature of at least 450° C. to about 900° C., and at a pressure of at least about 400 psig to about 1000 psig, to form a gas stream comprising a plurality of gaseous products comprising methane and at least one or more of hydrogen, carbon monoxide, carbon dioxide, hydrogen sulfide, ammonia and other higher hydrocarbons; and (F) at least partially separating the plurality of gaseous products to produce a product stream comprising a predominant amount of one of the gaseous products, wherein the exhaust produced from the at least partial combustion of the biomass feedstock is provided to the gasifier and the gas stream comprises carbon dioxide generated from the at least partial combustion of the biomass feedstock and the catalytic gasification of the carbonaceous feedstock.
 2. The process of claim 1, wherein the gas stream comprises carbon monoxide and hydrogen.
 3. The process of claim 1, wherein the reactor is a second gasifier or an oxygen combustor.
 4. The process of claim 3, wherein the reactor is a second gasifier, and the exhaust comprises synthesis gas.
 5. The process of claim 1, wherein the alkali metal gasification catalyst comprises a source of at least one alkali metal and is present in an amount sufficient to provide, in the carbonaceous feedstock, a ratio of alkali metal atoms to carbon atoms ranging from 0.01 to about 0.08.
 6. The process of claim 1, wherein the steam is generated within the reactor.
 7. The process of claim 1, wherein the heat energy is transferred to a heat exchanger in contact with a water source to produce the steam.
 8. The process of claim 1, wherein the biomass feedstock is in a particulate form.
 9. The process of claim 1, wherein the biomass feedstock comprises an aqueous slurry.
 10. The process of claim 1, wherein the product stream comprises a predominant amount of methane.
 11. The process of claim 1, further comprising the steps of: (C1) dividing the steam from step (C) into at least a first steam stream and a second steam stream; and (D1) introducing the second steam stream to a steam turbine to generate electricity; wherein the first steam stream is introduced into the gasifier in step (D).
 12. The process of claim 11, wherein the gas stream comprises carbon monoxide and hydrogen.
 13. The process of claim 11, wherein the reactor is a second gasifier or an oxygen combustor.
 14. The process of claim 13, wherein the reactor is a second gasifier, and the exhaust comprises synthesis gas.
 15. The process of claim 11, wherein the alkali metal gasification catalyst comprises a source of at least one alkali metal and is present in an amount sufficient to provide, in the carbonaceous feedstock, a ratio of alkali metal atoms to carbon atoms ranging from 0.01 to about 0.08.
 16. The process of claim 11, wherein the steam is generated within the reactor.
 17. The process of claim 11, wherein the heat energy is transferred to a heat exchanger in contact with a water source to produce the steam.
 18. The process of claim 11, wherein the biomass feedstock is in a particulate form.
 19. The process of claim 11, wherein the biomass feedstock comprises an aqueous slurry.
 20. The process of claim 11, wherein the product stream comprises a predominant amount of methane. 